Projects
Energy Efficiency and Sustainable Brewing Practices
Client: Wolf of the Willows Brewery
Industry: Brewing
Project: Heat Exchanger Replacement and Upgrade
Application: Wort Cooling & Liquor Preheating, Trade Waste Water Cooling
Location: Victoria
Products: IKP Brew Plate Exchanger
Background
Wolf of the Willows, an innovative brewery in Australia, was facing challenges related to energy efficiency and waste management in their brewing process. Breweries traditionally use a heat exchanger to cool the wort (unfermented beer) after the boiling stage by transferring its heat to preheat incoming liquor (brewing water). This process saves significant energy, as less heat is needed to bring the liquor to the required temperature for brewing. The client’s existing heat exchanger was no longer performing efficiently, leading to increased energy consumption and operational costs. Additionally, the disposal of trade waste water from keg washing posed a challenge, as the water needed to be cooled to regulated temperatures before discharge.
The Solution
The client approached InKorr to leverage our heat exchanger expertise in providing a comprehensive solution – from thermal sizing and design, to fabrication and testing of a brand new plate heat exchanger, with the added goal of increasing capacity for future expansion. The project unfolded in two key phases:
- Replacement of the Wort Cooling Heat Exchanger: InKorr supplied a brand new IKP Brew Plate Exchanger, specifically designed for the brewery’s wort cooling process. This fully-stainless heat exchanger provided highly efficient thermal transfer, significantly improving the wort cooling process. The recovered heat was effectively transferred to preheat the incoming liquor, reducing the energy required for the brewing process. This upgrade not only enhanced energy efficiency but also ensured consistent brewing temperatures, leading to improved product quality.
- Repurposing the Old Heat Exchanger: The old plate heat exchanger was adapted to cool trade waste water from the brewery’s keg washing and sterilizing operations. This innovative reuse allowed the brewery to efficiently lower the temperature of trade waste water, ensuring compliance with local environmental regulations before discharge. This not only helped the brewery achieve their target of environmentally friendly beer brewing but also allowed them to maximise use of existing assets.
Results
- Energy Efficiency: The new IKP Brew Plate Exchanger reduced the energy required for the wort cooling and liquor preheating process, contributing to lower operational costs and a more sustainable brewing process.
- Future-Proofing: With the increased capacity of the new heat exchanger, the client is well-positioned to expand their operations in the future without needing further modifications to their heat recovery system.
- Sustainability: The reconfiguration of the old heat exchanger for cooling trade waste water provided a cost-effective solution that extended the lifespan of existing equipment while ensuring regulatory compliance. This innovative approach minimized waste and supported the brewery’s commitment to sustainable brewing practices.
Conclusion
InKorr’s expertise in heat exchanger technology not only addressed the immediate energy efficiency and waste management challenges faced by Wolf of the Willows Brewery but also provided a scalable solution to support their future growth. Find out more or contact us for any heat exchanger replacement, upgrade, or refurbishment projects.
Glass Lined Equipment Service Highlights
InKorr has recently completed on-site service on a glass-lined decomposition reactor for one of our clients in the chemical process industry. Glass-lined equipment are commonly utilised in chemical and pharmaceutical plants as reactors, agitated mixers, storage tanks, and columns to handle highly corrosive fluids. The integrity of the glass lining in these vessels should be inspected and tested regularly as any undetected cracks, deformation, or pinholes can lead to heavy corrosion to the outer steel shell.
InKorr’s service technicians were mobilised on-site to inspect and test two units – one reactor in-situ and a spare unit in the storage yard. The glass lining for each unit was visually examined and any imperfections were noted down and reported.
Following the visual inspection, spark testing was performed on the vessel body and components including the agitator, manhole cover, nozzles, mechanical seal. etc. Spark testing is an effective method of identifying cracks and pinholes in the glass lining that often cannot be seen by the naked eye. The external metallic shell is charged and a current is detected wherever there is any damage on the surface of the glass lining.
During inspection and spark testing, a crack was found on a previously repaired section in the vessel. The old PTFE gasket and Tantalum plate were removed and the glass surface was carefully cleaned and prepared for a new repair. The new gasket and plate were moulded to securely fit against the concave surface of the glass and to completely cover the existing damaged area.
Following the on-site service, InKorr also supplied an identical spare of the mechanical seal flange. Through InKorr’s partnership with 3V Tech Glasscoat in Italy, we are able to offer re-glassing services and supply of replacements / spare parts for glass-lined components that cannot be repaired. Contact us for testing and repair services on your glass-lined equipment at https://inkorr.com.au/contact-us.
More information at https://inkorr.com.au/glass-lined-vessels.
Synth in Sync, Onsite in NSW
Recently InKorr (in collaboration with our partner Mersen) completed an Onsite project for a client in the Chemical manufacturing industry where we performed a complete strip-down refurbishment of a Hydrochloric Acid Synthesis Unit.
InKorr and the client worked together prior to the shutdown works preparing all the necessary staffing, a detailed plan of works from start to finish, required tools & equipment, replacement parts (Graphite components, gaskets & bolt sets) and contingency plans if any issues were to arise throughout the critical stages of works.
All components were disassembled and removed from their Skid, for detailed inspection, repair/refurbishment and replacement where required.
Due to the importance this piece of equipment holds in our clients production, InKorr were tasked with completing this project in as short a time as possible.
Performing back to back day and night shifts, and supervising a total of 20 people working together, the planning and preparations for this project proved well worth it.
A window of approximately 7 days was estimated to complete the job, which was achieved & bettered by almost a whole day!
Following the completion of the refurbishment works, the unit was tested via hydrostatic pressure test, even and level absorption water distribution & full operational testing. All of which passed with great success.
InKorr then assisted in the restart and commissioning of the unit back into service, followed by provision of a detailed service report, testing certificates along with recommendations for ongoing maintenance, future works and spare parts.
InKorr are proud to confirm, following a debrief and check up meeting with the client, that they are once again producing great quality product for their customers! We look forward to continuing our support with this client.
Cotton Seed Distributors (NSW, Aus) – HCl Project Completion
After a couple of years from thought to design to execution and finally to operation, the HCl distillation plant feeding the new delinting system has finally started operation! We would like to congratulate all of participants from CSD / Advitech / Mersen / InKorr for their hard work in getting this system up and running. Within the past week, the gas plant, a one of a kind for Oceania, has successfully injected the specified quantity and quality of HCl gas into the delinting drums as planned. The gas has done its part to assist in the production of the world’s best cotton, made in Australia!
We look forward to providing ongoing support in order to keep the gas plant operating in peak condition for years to come. Please enjoy the view of the plant during the day as well as at night!
Full Refurb on “mini” HCl Unit
The InKorr team was asked to take 2 damaged HCl synthesis units, scour them for usable parts and then build one quality, working piece of equipment. HCl synthesis units are used to produce HCl gas from chlorine and hydrogen. The gasses are burned together in the absence of oxygen to produce HCl. The challenging nature of such equipment has to do with the heat generated in the flame of the reaction (roughly 2,000 degreed Celsius) and the fact that HCl is an extremely corrosive material.
One of the more complicated aspects of maintaining this equipment is caring for, testing, and even in some cases repairing the graphite components. Impregnated graphite is necessary for its full resistance to HCl at any concentration and any temperature. Despite its outstanding corrosion resistance, it is susceptible to mechanical damage. This means that handling these parts takes experience and know-how!
The fully refurbished equipment was shipped today to our client in Australia for use in their factory in the agriculture sector. One repair successfully out the door. Now, on to the next project!
